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Sunsailor: Solar Powered UAV Faculty of Aerospace Engineering, Technion IIT, Haifa, Israel, Students’ Project

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Sunsailor: Solar Powered UAV Faculty of Aerospace Engineering, Technion IIT, Haifa, Israel, Students’ Project SunSailor: Solar Powered UAV Faculty of Aerospace Engineering, Technion IIT, Haifa, Israel, Students’ Project A. Weider, H. Levy, I. Regev, L. Ankri, T. Goldenberg, Y. Ehrlich, A. Vladimirsky, Z. Yosef, M. Cohen. Supervisor: Mr. S. Tsach, IAI ABSTRACT sources in subsonic aviation. Aside from This paper summarizes the final project potential military applications, civil of undergraduate students team at the demands for Long Endurance UAVs are Faculty of Aerospace Engineering at the growing daily. These will be able to Technion IIT, Haifa, Israel. The team replace communication, scientific and was formed to design, build, test and fly environmental satellites in the future, a Solar Powered Unmanned Aerial suggesting a cost effective replacement Vehicle with the final goal of breaking to satellites technology. They will be the world record for distance flight under able to monitor large crops, forests and certain limitations. Until this moment wildlife migration. The Solar Powered two UAVs were built at the Technion UAVs use an unlimited power source for Workshop. The first flew its first solar propulsion and other electrical systems. flight on June 29th 2006. It crashed on its Using Photovoltaic (PV) cells, solar third solar flight. The second was built in radiation is converted into electric power 54 days, flew and crashed on its maiden and then converted into kinetic energy solar flight. The third UAV is under by the electric motor. The main construction. difficulty as for today is the low efficiency of both PV cells and motors. 1 Introduction This paper presents the development of The FAI (The World Airsports the Sunsailor, a Solar Powered UAV, Federation) world record for the F5-SOL discussing the following issues: Category today was set on June 13, 1997 - Project objectives and and is 48.21 Km. Our goal was to set a requirements. new record at 139 Km. The whole flight - UAV’s design. must be radio controlled and no - Manufacturing and Ground autopilots of any kind may be used to fly Tests. or help flying the UAV. The route for - Solar Array design and tests the record setting flight was decided to - Flight Tests be over the Arava highway, Israel, from Hatzeva to Eilot. Global Radiation Analysis for the flight route showed best conditions from June to August. Other main objectives of the project were proving the feasibility of Solar Powered, Low Altitude Long Endurance UAVs at certain design limitations and advancing the use of clean power Figure 1: Sunsailor2 Solar flight 1 2 Project Objectives - The UAV will be escorted by a The project has a number of objectives: vehicle carrying 3 pilots and a 1. Enabling the students to integrate designated driver. Therefore ground the knowledge acquired in their speed must be at least 50kph as the academic studies and law requires such minimum speed experiencing an air vehicle along this highway. development, manufacturing and - Flight Altitude will not exceed testing process. 500ft above ground level and 2. Introducing the students airborne therefore will not interfere with civil systems and technologies not aviation although the flight path is included or briefly mentioned in just under the low civil routes in the the undergraduate academic area. studies (PV cells, autopilot, - Traffic Police and Air Force control electric motors, etc.) will be notified about the flight. 3. Setting a new world record for lightweight Solar Powered UAV. 4. Advancing clean power sources for aviation purposes in particular. 3 Design Requirements 3.1 Aircraft Requirements • Electrical motor propulsion. • Radio controlled flight without the help on any telemetry. • Maximum upper surfaces area of 1.5m2. • Maximum Weight of 5 Kg. • Only Solar Cells are permitted as the propulsion system power source. 3.2 Flight Plan - The Sunsailor UAV will be hand- launched and take off from Hatzeva Junction, a few kilometers south of the dead sea, Israel. Most of the flight path is 50-100 meters west of the Highway. At some points the path will cross the highway to the east to avoid any near cliffs. Figure 2: Flight Plan for record setting. 139Km. - General heading is south in order to fly downwind. - Belly landing will be performed on a soft surface near Eilot, a few kilometers north of Eilat. 2 4 Work Organization and Timeline landing and takeoff concepts, performance, subsystems, solar array 4.1 Team Architecture design, propulsion and design for As the project involved many aspects of manufacturing. A project manager was design and manufacturing each of the selected to integrate the different fields students was given several different and supervise acquisition and fields in design and all worked on manufacturing. His responsibility was to manufacturing once design and organize work, set the time frame and acquisition were done.4 Pilots were priorities. An IAI advisor directed the chosen by reputation and flying group to achieve each milestone in the experience with electric sailplanes. The most efficient way, while assimilating design aspects were geometry, the industry’s project conducting aerodynamics and stability, structure, methods. Shlomo Tsach Advisor Avi Wieder Project manager Design Manufacturing Tests Pilots Geometry Aerodynamics&Stability Workshop Managers Wing&Boom NDT Roi Dor Alexander Vladimirsky, Yorai Aherlich,Maxim Cohen& Hanan Levy& Tamar Goldenberg& Hanan Levy&Liran Ankri Ziv Yosef Avi Weider Idan Regev Structure Landing&Takeoff Concepts Structure Motor&Propellers Yonatan Segev Idan Regev & Ziv Yosef All Team Students& Hanan Levy Tamar Goldenberg Amit Wolf Performance Subsystems&Project Site Solar Array Ido Segev Idan Regev Liran Ankri Solar Cell&Array Idan Regev& Idan Regev& Hanan Levy Hanan Levy Solar Array Design Propulsion Shlomi Chester Idan Regev& Avi Weider Subsystems EMI Hanan Levy Shlomi Chester& Idan Regev& Tomer Cohen Hanan Levy Design for Manufacturing Avi Weider& Hanan Levy Flight Tests Engineer Idan Regev Figure 3: Team Architecture 4.2 Schedule During the weekly meeting the team Design was concluded after two full reviewed each field’s progress and semesters. First semester was dedicated decided the next assignments. The to preliminary design and was concluded project manager set priorities and in a Preliminary Design Review (PDR). summarized the meeting conclusions. As In the second semester a comprehensive acquisition and cutting of the solar cells design for manufacturing was completed took a very long time, first solar flight and manufacturing began. The semester was delayed by one month. work was concluded in a Critical Design Review (CDR). 3 Figure 4 : Semester 1&2 Gant Charts. conventional tail vs. “V” shaped tail, low 5 Air Vehicle Description AR vs. high AR and small vs. large ailerons. 5.1 Conceptual Design Different takeoff and landing concepts As Efficiency of commercial solar cells were also examined. The team chose the is still very low, the platform must be hand-launched takeoff and belly landing. some sort of a sailplane with high This way there is no need for gear or the Aspect Ratio (AR) and high lift over excess weight of any other landing Drag (L/D). Three configurations were device. examined, a conventional sailplane, flying wing and a twin boom configuration. After evaluating the advantages and disadvantages of each configuration, the conventional approach was chosen due to lower Drag (D) and higher cruise velocity. Also this approach is well known for both theory and manufacturing, thus minimizing the risks, times and costs. Figure 5: Three configurations and the final After deciding on the conventional Sunsailor concept. configuration the team checked performance for double vs. single motor, 4 5.2 Aircraft’s Definition Power Plant (for Sunsailor1) Electric Motor: Hacker B50-13S Max T.O Weight: 3.6[Kg] Speed Controller: Hacker X-30 Length: 2.2[m] Gear Ratio: 6.7:1 Wing Airfoil: SD7032 Propeller: 15”X10” Span: 4.2[m] Wing Area: 1.35[m2] Solar Array (Sunsailor1/Sunsailor2) Aspect Ratio: 13.15 PV’s Area: 0.943/1.097[m2] Wing Dihedral: 3.5◦ PV’s Efficiency: 21% Tail Airfoil: NACA0007 PV’s Weight: 0.66/0.77[Kg] Horizontal Tail AR: 5.77 PV’s Maximum Power: 100/140[W] Tail Aperture: 90◦ 5.3 Aircraft’s Geometry Figure 6: Sunsailor Isometric View Figure 7: Sunsailor Geometry 5 5.4 Characteristic Parameters Sunsailor1 Weight Breakdown Moment Arm [mm] Weight Component b C = 0.0030 [gr X m] from Firewall [gr] = 2.18 fe 762.34 543.32 1403.1 Wing Swet 117.30 509.18 230.3 Fuselage ⎛⎞T C=170 counts Structure D0 [ ] ⎜⎟ = 0.3 101.60 1270.00 80 Tail Boom ⎝⎠W takeoff 159.84 2070.41 77.2 Tail Servos WK⎡⎤gf ⎛⎞L = 2.66 = 20.23 42.70 610.00 70 Ailerons Servos ⎢⎥2 ⎜⎟ Smwing ⎣⎦⎝⎠D max 84.40 2110.00 40 Tail Servos Avionics & Table 1: Sunsailor’s Characteristic Parameters Autopilot&Com.+A Subsystems 164.70 610.00 270 nt. 5.5 Performance 92.00 255.56 360 Systems Battery 4.90 20.00 245 Electric Motor The basic flying qualities could be tested 1.90 50.00 38 Speed Controller Propulsion during flight using telemetry data and 0.30 15.00 20 Prop+Spinner are presented here for both design and 410.52 622.00 660 PV cells Power Supply tested values: 45.00 450.00 100 Wiring Total Moment 1987.50 3593.6 Total Weight [gr] Quality Designed/Tested [Kg X m] Stall Airspeed: 12/13 [knots] From Max. Airspeed: 33/38 [knots] motor 553.05 mm Firewall Xcg Cruise Airspeed: 25/23 [knots] From L.E 32.20 %chord Max. Climb Rate: 300/240 [ft/min] From L.E 46.20 %chord Xn Solar Array Power 14.00 %chord Stability Gap Required for takeoff: 50/70 [Watt] Table 2: Sunsailor1 Weight Breakdown Wing Max. Load Factor: 2.8/4 6 Aerodynamic Design 5.6 Weight & C.G Estimation Vs.
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